Method for producing nonwoven fabric composite having multi-directional stretch properties utilizing a cellular or foam layer

ABSTRACT

A non-woven fabric laminate having stretch properties constructed using hydroentanglement methods is disclosed. The laminate is comprised of at least two layers and utilizes a foam layer as a component in the preferred embodiment, replacing conventional use of fibrous materials. A superior elastomeric fabric utilizing an open or closed cell foam layer as one element of the composite structure and as the elastic member of the fabric results in superior fabric characteristics when compared to similar hydroentangled fabrics which are constructed from fibrous materials.

REFERENCES TO PRIOR APPLICATION

This application is a Divisional patent application of Ser. No.08/929,229, filed Sep. 9, 1997 now U.S. Pat. No. 6,074,966. The parentapplication claims the benefit of the filing date of the applicant'sProvisional Patent Application No. 60/024,721 filed Sep. 9, 1996.

BACKGROUND OF THE INVENTION

The field of nonwoven fabric laminates has been well developed to devisefabrics with both machine and cross directional stretch propertiesutilizing conventional lamination which consists of heat and/oradhesives to produce the final product. The present state of the artincludes use of multi-layer fabrics of fibrous composition to providefor the entanglement process. Prior art utilizes composites that areformed by employing a multitude of layers including elastomericspunbond, elastomeric fibers including natural and synthetic fibers, andfilms. Certain combinations of such fabrics are typically laminated,glued together requiring a more costly manufacturing process.

The prior art utilizes hydroentanglement to entangle fibers into anelastomeric spunbond and some of these fibers may be thermobond fibersor hydroentangle elastomeric fibers together to form a compositematerial.

SUMMARY OF THE INVENTION

The present invention provides for a resilient elastomeric comprised ofsoft foam, either open or closed cell, as a composite member to providestrength to the total composite. Disclosed is an elastomeric compositestructure utilizing at least one cellular structure material as acomposite member such that the individual walls of each cell in suchstructure could behave like an individual fiber and could thus beentangled using otherwise conventional methods of entanglement.

It is the object of the present invention to provide a superiorelastomeric nonwoven fabric and to provide a method of production ofsame that incorporates foam to be used as both a strength and resilientmember in the composite fabric. The disclosed invention provides forsuperior fabric by utilizing hydroentanglement and at least one layer ofsuitable cellular material, preferably a foam, a backing wire utilizingeither flat wire, medium knuckle wire or high knuckle wire, and at leastone layer of wood pulp tissue fabric to be entangled utilizing ahydroentanglement process.

The present invention is a nonwoven, relatively strong web, utilizing atleast one layer of elastic foam as a constitute composite member. Thepresent disclosure describes a resulting fabric and a method ofproducing the fabric resulting in a fabric produced by ahydroentanglement process that provides superior characteristics ascompared to similar processes utilizing composite fabrics utilizingfibrous materials as conventionally provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration showing the layering position of compositelayers of the constitute elements comprising the fabric in relation tothe backing or forming wires.

FIG. 2 is a pictorial diagram of an existing hydroentanglementprocessing machinery.

FIG. 3 is a schematic view of a proposed process illustrating the layersof material in the application process.

FIG. 4 is a schematic view of the process illustrating a two-sidedentanglement.

FIG. 5 is a schematic view of the resulting fabric illustrating thethickness of the resulting product.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The Prior Art has failed to identify a composite fabric, or a method ofmaking a composite fabric which would yield the best qualities that anelastic member, along with the properties of a fibrous material as asecond member of the composite. Foam materials are generally a cellularstructure. Each wall of a cell can be made to behave like an individualfiber and accordingly can be entangled with other fibers. Foam cellswould continue to contain their windows in that the film between thecell walls remain intact even if a foam cell has been penetrated by afiber material as a result of some process. Naturally, and in accordancewith the invention, a given foam material could be optimized for theappropriate entanglement parameters depending on the foams density,thickness, softness (spring rate) and pore size. Foam products developedto practice the present invention could be tailored for an optimumhydrophobicity or hydrophilicity. By utilizing foam with various stretchqualities and stretch recovery qualities, a final product with thedesired properties can easily be obtained in accordance with the presentinvention. This cellular structure of most foams are aligned such thatan entangled fiber is so entangled, in a tortuous path, because of thedepth of the many cells breached, by the insertion of fibers through anentanglement process.

Turning to FIG. 1, a pictorial representation of the layering formatnecessary to practice the present invention illustrated by severalexamples. Two wood pulp fiber layers are shown on top of a foam layerutilizing either open or closed cell foam. In the diagrams, two layersor wood pulp tissue of 20 grams/m² were combined, although a singlelayer of 40 grams/m² provides the same or similar end products. Inexample 2, flat wire 10 is utilized as a backing in thehydroentanglement process to provide a bearing surface for water jets 20to work three separate constitute layers of the material. In example 4,the same two layers of wood pulp fabric are utilized against a thirdlayer of a suitable foam utilizing a medium knuckle wire 12 as a bearingsurface against which water jets 20 work the material forhydroentanglement. Good results have also been obtained by utilizing thesame layering of material as shown in example 6 utilizing high knucklewire 14 to provide courser texturing of the final product. It is alsopossible to layer wood pulp fabric on either side of the center layer ofsuitable foam material as shown in example 8 against flat wire 16 toproduce a useful composite.

FIG. 2 illustrates conventional and well-known hydroentanglementprocessing systems which work fibrous layers of nonwoven materials intoa single element exiting processor 30 at 32. Backing wire 34 is shownover the bearing surface 36. The use of the hydroentanglement processcurrently utilized to hydroentangle fibrous layers of fabric andmaterial can be directly applied to the present invention tohydroentangle fibrous materials and layers into a cellular structuredmaterial as in a foam. Little or no change is necessary to the availableequipment to produce the end product.

Considering FIG. 3 there is shown a simple schematic of the processillustrating a layer of fibrous natural or synthetic material as thefirst layer, a cellular structured material such as a foam as the secondlayer, and an entanglement backing wire as offered in FIG. 1. Usingconventional hydroentanglement processing machinery as illustrated inFIG. 2, a vacuum box is utilized beneath the entanglement wire for thepurpose of enhancing the working of the material the side of the fabricopposite of the hydroentanglement water jets shown in FIG. 3. It is alsopossible to utilize two-sided entanglements as shown in FIG. 4. Thehydroentangled composite fabric resulting from the process depicted inFIG. 3 is reversed after the first processing, it is possible tohydroentangle a second layer of fibrous material such as wood pulp orother fibrous layers by utilizing the identical process of entanglementthus producing a two-sided layer.

The use of a cellular composite layer for the entanglement process, thefinal thickness of the material is reduced, owing partially to thecellular structure being more concentrated and more microporous allowingfor finer filtration of particles if the resulting product is used in afilter process. In the “z” dimension the spring rate of the fabric isincreased and exhibits more stored bounce back.

It is believed by the inventor that by the utilization of open or closedcell foams in the hydroentanglement process, the embedded fibers fromthe fibrous layers are locked into the cell structure and are lesseasily dislodged due to a tortious path through the “z” direction, andthe cell pour size reduction. Modification of the backing wire as shownin FIG. 1 assist in producing different textures or patterns as might bedesirable in different applications.

The process of making an improved nonwoven fabric includes applying ahydroentanglement process and the application of water jet technology toat least one layer of fibrous material such as wood pulp, and a secondlayer of a cellular structured material such foam, against a third layerof a backing wire, compressing the constitute elements just describedinto a singular, non-woven fabric product.

Details of the examples of preferred embodiment regarding the densitiesand the type of materials which appear to provide a superior product arecontained in the following examples, which includes certainillustrations of parameters used and obtained in practicing theinvention. Included are specific examples of combinations which fail toproduce a fabric in accordance with the invention.

EXAMPLE 1

Sample ID#A-12/20/96

Description

One piece of woodpulp tissue was placed on top of foam and this woodpulptissue was entangled into the foam via hydroentanglement. The foam was“flipped over” and the other piece of woodpulp tissue was placed on theback side of the foam and entangled into the foam via hydroentanglement.The resulting structure contained woodpulp fibers on both sides of thefoam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/sq. Meter per sheet.

B. Foam—Foamex VPF@—1.1 lbs/cubic foot density

manufactured in Toupolo, Miss.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (Pores per linear inch)),

ILD (Indention Load Deflection)=6-7,

initial thickness=0.125 inches thick,

basis weight=55.9 grams/sq. Meter.

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

400, 600, 600, 600 PSI

Flip composite over

400, 600, 600, 600 PSI

Total energy=0.211 HP-HR/LBM

EXAMPLE 2

Sample ID# B-12/20/96

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement.Samples B, C, and D-12/20/96 define an energy curve for putting variousamounts of hydroentanglement energy into the same construction. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/sq. Meter per sheet.

B. Foam—Foamex VPF@—1.2 lbs/cubic foot density

manufactured in Toupolo, Miss.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=6-7,

initial thickness=0.1875 inches thick,

basis weight=91.5 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

400, 500, 600, 600, 600 PSI

Total energy=0.093 HP-HR/LBM

EXAMPLE 3

Sample ID# B-12/20/96

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement.Samples B, C, and D-12/20/96 define an energy curve for putting variousamounts of hydroentanglement energy into the same construction. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/sq. Meter per sheet.

B. Foam—Foamex VPF@—0.7 lbs/cubic foot density

manufactured in Toupolo, Miss.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=6-7,

initial thickness=0.125 inches thick,

basis weight=35.6 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

400, 500, 600, 600, 600 PSI

Total energy=0.163 HP-HR/LBM

EXAMPLE 4

Sample ID# C-12/20/96

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement.Samples B, C, and d-12/20/96 define an energy curve for putting variousamounts of hydroentanglement energy into the same construction. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/sq. Meter per sheet.

B. Foam—Foamex VPF@—1.2 lbs/cubic foot density

manufactured in Toupolo, Miss.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (indention Load Deflection)=6-7,

initial thickness=0.1875 inches thick,

basis weight=91.5 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

400, 600, 800, 1,000, 1,000, 1,000, 1,000, 1,000 PSI

Total energy=0.301 HP-HR/LBM

EXAMPLE 5

Sample ID# D-12/20/96

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement.Samples B, C, and D-12/20/96 define an energy curve for putting variousamounts of hydroentanglement energy into the same construction. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/sq. Meter per sheet.

B. Foam—Foamex VPF@—0.7 lbs/cubic foot density

manufactured in Toupolo, Miss.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=4-6,

initial thickness=0.125 inches thick,

basis weight=35.6 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

400, 600, 800, 1,000, 1,000, 1,000, 1,000, 1,000 PSI

Total energy=0.523 HP-HR/LBM

EXAMPLE 6

Sample ID# D-12/20/96

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement.Samples B, C, and D-12/20/96 define an energy curve for putting variousamounts of hydroentanglement energy into the same construction. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/sq. Meter per sheet.

B. Foam—Foamex VPF@—1.2 lbs/cubic foot density

manufactured in Toupolo, Miss.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (indention Load Deflection)=6-7,

initial thickness=0.1875 inches thick,

basis weight=91.5 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

700, 1,200, 1,200, 1,200, 1,200, 1,200, 1,200, 1,200 PSI

Total energy=0.457 HP-HR/LBM

EXAMPLE 7

Sample ID# D-12/20/96

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement.Samples B, C, and D-12/20/96 define an energy curve for putting variousamounts of hydroentanglement energy into the same construction. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/sq. Meter per sheet.

B. Foam—Foamex VPF@—0.7 lbs/cubic foot density

manufactured in Toupolo, Miss.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=4-6,

initial thickness=0.125 inches thick,

basis weight=35.6 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

700, 1,200, 1,200, 1,200, 1,200, 1,200, 1,200, 1,200 PSI

Total energy=0.795 HP-HR/LBM

EXAMPLE 8

Sample ID# E-12/20/96

Description

A layer of carded cotton batting was placed on top of foam and thiscarded cotton was entangled into the foam via hydroentanglement. Theresulting structure contained cotton fibers on only one side of the foamwith a defined level of penetration into the foam.

Materials

A. Carded cotton batting—fiber length approximately 1.0 inches; 15grams/sq. Meter.

B. Foam—Foamex VPF@—1.1 lbs/cubic foot density

manufactured in Toupolo, Miss.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=6-7,

initial thickness=0.125 inches thick,

basis weight=55.9 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000 PSI

Total energy=0.693 HP-HR/LBM

EXAMPLE 9

Sample ID# F-12/20/96

Description

A layer of carded polyester batting was placed on top of foam and thispolyester was entangled into the foam via hydroentanglement. Theresulting structure contained polyester fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Carded polyester batting—fiber length approximately 1.50 inches;

Denier=1.5 dpf (denier per filament);

15 grams/sq. Meter.

B. Foam—Foamex VPF@—0.7 lbs/cubic foot density

manufactured in Orange, Calif.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=4-6,

initial thickness=0.125 inches thick,

basis weight=35.6 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000 PSI

Total energy=0.971 HP-HR/LBM

EXAMPLE 10

Sample ID# G-12/20/96

Description

A layer of carded cotton batting was placed on top of foam and thiscarded cotton was entangled into the foam via hydroentanglement. Theresulting structure contained cotton fibers on only one side of the foamwith a defined level of penetration into the foam.

Materials

A. Carded cotton batting—fiber length approximately 1.0 inches; 15grams/sq. Meter.

B. Foam—Foamex VPF@—0.7 lbs/cubic foot density

manufactured in Orange, Calif.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=4-6,

initial thickness=0.125 inches thick,

basis weight=35.6 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000 PSI

Total energy=0.971 HP-HR/LBM

EXAMPLE 11

Sample ID# H-12/20/96

Description

Two layers of woodpulp tissue are placed on top of a lightweightspunbond polypropylene material. This layered assembly is then placed ontop of the foam and the whole composite is subjected to entanglement,from top side hydroentanglement only. The resulting structure is verysecure and integrated with the woodpulp “anchoring” the spunbond to thefoam, thus giving the composite more strength and less elongation.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/sq. Meter per sheet.

AA. Spunbond polypropylene co-polymer; Amoco RFX@; 20 grams/sq. Meterper sheet 3-4 dpf (denier per filament),

B. Foam—Foamex VPF@—0.7 lbs/cubic foot density

manufactured in Orange, Calif.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=4-6,

initial thickness=0.125 inches thick,

basis weight=35.6 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

700, 1,200, 1,200, 1,200, 1,200, 1,200, 1,200, 1,200 PSI

Total energy=0.629 HP-HR/LBM

EXAMPLE 12

Sample ID# J-12/20/96

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement. Thissample was mounted on a coarse wire (20×20 mesh) and the entanglementwas performed on the top side only. The resulting structure containedwoodpulp fibers on only one side of the foam with a defined level ofpenetration into the foam. This structure was also unique in that thesample contained areas of “peaks and valleys” thus creating athree-dimensional topography in the final composite structure.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/sq. Meter per sheet.

B. Foam—Foamex VPF@—0.7 lbs/cubic foot density

manufactured in Orange, Calif.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=4-6,

initial thickness=0.125 inches thick,

basis weight=35.6 grams/sq. Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=20×20 mesh synthetic (Polyester/nylon).

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000 PSI

Total energy=0.788 HP-HR/LBM

EXAMPLE 13

Sample ID#K-12/20/96

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement. Theentanglement was performed on the top side only. The resulting structurecontained woodpulp fibers on only one side of the foam with a definedlevel of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/square Meter persheet.

B. Foam—Foamex VPF@—0.6 lbs/cubic foot density (Reflex),

manufactured in Orange, Calif.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Load Deflection)=3-4,

initial thickness—0.0625 inches thick,

basis weight—15.26 grams/square Meter.

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, PSI

total energy=0.890 HP-HR/LBM

EXAMPLE 14

Sample ID#K1-12/20/96

Description

One piece of woodpulp tissue was placed on top of foam and this woodpulptissue was entangled into the foam via hydroentanglement. The foam was“flipped over” and the other piece of woodpulp tissue was placed on theback side of the foam and entangled into the foam via hydroentanglement.The resulting structure contained woodpulp fibers on both sides of thefoam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/square Meter persheet.

B. Foam—Foamex VPF@—0.6 lbs/ cubic foot density (Reflex),

manufactured in Orange, Calif.,

non-reticulated (contains cell walls),

fire pore (approx. 100 PPI (pores per linear inch)),

ILD (Indention Loan Deflection)=3-4,

initial thickness=0.0625 inches thick,

basis weight=15.26 grams/ square Meter.

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, PSI, then flip over and add . . . 1,000,1,000, 1,000, 1,000, PSI

total energy=0.890 HP-HR/LBM

EXAMPLE 15

Sample ID# L-12/20/96

Description

Three pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/square Meter persheet.

B. Foam—Foamex VPF@—0.6 lbs/cubic foot density (Reflex),

manufactured in Orange, Calif.,

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch))

ILD (Indention Load Deflection)=3-4,

initial thickness 0.0625 inches thick,

basis weight=15.26 grams/square Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, PSI

total energy=0.653 HP-HR/LBM

EXAMPLE 16

Sample ID# FAILURE #1 (Pore size too large, too many large holes,entanglement not fully integrated into the “crators” of the foam).

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement. Theresulting structure contained woodpulp fibers on only one side of thefoam was a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/square Meter persheet.

B. Foam—Foamex VPF@—0.8 lbs/cubic foot density.

manufactured in Orange, Calif.

non-reticulated (contains cell walls).

Mid pore (approx. 40 to 50 PPI (pores per linear inch)).

ILD (Indention Load Deflection)=4-6,

initial thickness=0.250 inches thick.

basis weight=81.37 grams/square Meter.

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, PSI

total energy=0.405 HP-HR/LBM

EXAMPLE 17

Sample ID# FAILURE #2 (ILD too high—foam too rigid/stiff to allowentanglement—water just bounced-off the composite during entanglingattempt).

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/square Meter persheet.

B. Foam—Foamex AquaZone@—3.2 lbs/cubic foot density.

manufactured in Essington, Pa.

non-reticulated (contains cell walls).

super fine pore (greater than 100 PPI (pores per linear inch)).

ILD (Indention Load Deflection)=10-12,

initial thickness=0.125 inches thick,

basis weight=162.7 grams/square Meter.

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under a jet strip approximately 25 inches to 45 inchesof water column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, PSI

total energy=0.242 HP-HR/LBM

EXAMPLE 18

Sample ID# I-12/20/96

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/square Meter persheet.

B. Foam—Foamex VPF@—0.5 lbs/cubic foot density,

manufactured in Essington, Pa. (only lab samples available),

non-reticulated (contains cell walls),

fine pore (approx. 100 PPI (pores per linear inch))

ILD (Indention Load Deflection)=4,

initial thickness=0.125 inches thick,

basis weight=25.43 grams/square Meter

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under jet strip approximately 25 inches to 45 inches ofwater column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, PSI

total energy=0.657 HP-HR/LBM

EXAMPLE 19

Sample ID# FAILURE #2 (ILD too high—foam too rigid/stiff to allowentanglement—water just bounced-off the composite during entanglingattempt).

Description

Two pieces of woodpulp tissue were placed on top of foam and thiswoodpulp tissue was entangled into the foam via hydroentanglement. Theresulting structure contained woodpulp fibers on only one side of thefoam with a defined level of penetration into the foam.

Materials

A. Woodpulp—Northern softwood pulp tissue—20 grams/square Meter persheet.

B. Foam—Foamex AquaZone@—1.7 lbs/cubic foot density.

manufactured in Essington, Pa.

non-reticulated (contains cell walls).

super fine pore (greater than 100 PPI (pores per linear inch)).

ILD (Indention Load Deflection)=10-12,

initial thickness=0.125 inches thick,

basis weight=86.46 grams/square Meter.

Process

A. Laboratory hydroentanglement system approx. 20 inches wide.

B. Entanglement backing wire=100×100 mesh stainless steel.

C. Entanglement jet strips=60 nozzles/inch; double rows: each nozzlehaving a diameter of 0.004 inches.

D. Machine line speed held constant at 50 feet/minute.

E. Vacuum level under a jet strip approximately 25 inches to 45 inchesof water column.

F. Number of passes under a jet strip/jet strip pressure/totalentanglement energy.

1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, 1,000, PSI

total energy=0.389 HP-HR/LBM

The inventor has also determined foams with an indentation forcedeflection (IFD), previously known as ILD, of between 7.0 and 4.0provides suitable candidates for use in the process described.

Considering the details specifically, it has been noted by the inventorthat there has been cellular structured material, and specifically foammaterials which have not functioned well to provide a final productdescribed in this paper. In the past, and in the prior art, foams ofgreater density such as that available from Woodbridge foam fabricating,their product SM 64, does not function well, since the end productresulting from attempting to utilize the foam in a hydroentanglementprocess does not tangle adequately to provide a stable final product.The inventor has found that foams such as those marketed by Foamex,their variable pressure foam (VPF), works well as the cellular structurecomponent in the process disclosed. Both natural fibers, such as woodpulp, cotton and rayon or synthetic fibers of the polypropylene,polyester, polyethylene family works well. The inventor has observedthat foam densities of around or about 1.7 pounds per foot³ down to andincluding a density of approximately 0.5 pounds per cubic foot provide aconsiderable improvement in the successful entanglement of fiber layersinto foam. Although it does not matter whether the foam used forentanglement is of an open or a closed cell structure, foam densitiesappear to make a critical difference in hydroentanglement fibrousmaterials, whether natural fibers or synthetic fibers.

The cell structure of the foam is believed to provide a fiber lockingmechanism to maintain the entanglement, without the use ofthermo-meltable fabrics or by component fibers also known as sheath/corefibers or binder fibers utilized in the prior art. It is not necessary,in the disclosed invention, to utilize adhesives or short fibers tomaintain the entanglement.

The resulting product is superior in various qualities including verylow linting, superior elastomeric properties, and leaves very littledebris in the de-watering or drying process.

Although the present invention has been described with reference to theparticular embodiments herein set forth, it is understood that thepresent disclosure has been made only by way of example and thatnumerous changes in details of construction may be resorted to withoutdeparting from the spirit and scope of the invention. Thus, the scope ofthe invention should not be limited by the foregoing specifications, butrather only by the scope of the claims appended hereto.

What is claimed as being new, useful and desired to be protected byLetters Patent of the United States is as follows:
 1. A method for theproduction of fiber-implanted, elastomeric nonwoven fabric comprisingthe steps of: a.) depositing a single layer of foam onto awater-permeable woven cloth wire having a defined mesh pattern; b.)laying a fibrous web upon the single layer of foam; c.) pre-wetting theinitial material of foam and fibrous web prior to water jetentanglement; d.) subjecting the initial material to a plurality ofwater jet streams that are continuous and without pattern modification,that impinge the initial material from the fibrous web side while havinga vacuum pulled from the foam side to enhance fiber penetration, suchthat; e.) the fibrous web is fully entangled into the foam structure,the foam structure height is collapsed, and the final structure is afully-integrated fiber/foam composite.
 2. A method for the production offiber-implanted, elastomeric nonwoven fabric according to claim 1, wherethe water-permeable woven cloth wire is a fine mesh wire of 100×100plain weave.
 3. A method for the production of fiber-implanted,elastomeric nonwoven fabric according to claim 1, where thewater-permeable woven cloth wire is a fine mesh wire of 102×78 twillweave.
 4. A method for the production of fiber-implanted, elastomericnonwoven fabric according to claim 1, where the water-permeable wovencloth wire is a coarse mesh wire of a range between 13×13 to 80×80 plainweave.
 5. A method for the production of fiber-implanted, elastomericnonwoven fabric according to claim 1, where the water-permeable wovencloth wire is a 2, 3, 4, or 5-shed papermaking weave.
 6. A method forthe production of fiber-implanted, elastomeric nonwoven fabric accordingto claim 1, where the fibrous web is deposited onto one side of the foammaterial in a dry, tissue form prior to pre-wetting and subsequent waterjet entanglement.
 7. A method for the production of fiber-implanted,elastomeric nonwoven fabric according to claim 1, where the fibrous webis deposited onto one side of the foam material in a dry, individualfiber form prior to pre-wetting and subsequent water jet entanglement.8. A method for the production of fiber-implanted, elastomeric nonwovenfabric according to claim 1, where the fibrous web is deposited onto oneside of the foam material in a wet, individual fiber slurry form priorto water jet entanglement.
 9. A method for the production offiber-implanted, elastomeric nonwoven fabric according to claim 1,whereby at the completion of this entanglement, a second fibrousmaterial is deposited onto the other side of the foam material and it isentangled into the second foam side according to the methodologydescribed in claim 1, thus capturing the foam material between twofibrous layers.
 10. A method, according to claim 9, where thewater-permeable woven cloth wires are plain weave wires in the range of13×13 to 100×100 mesh.
 11. A method, according to claim 9, where thewater-permeable woven cloth wires are a twill weave of 102×78 mesh. 12.A method, according to claim 9, where the water-permeable woven clothwires are chosen from a papermaking weave in the range of a 2, 3, 4, or5-shed construction.
 13. A method, according to claim 9, where thewater-permeable woven cloth wires used in entanglement are identical forboth entanglement procedures into each side of the foam.
 14. A method,according to claim 9, where the water-permeable woven cloth wires usedin entanglement are dissimilar for each of the entanglement proceduresinto each side of the foam.
 15. A method, according to claim 9, wherethe fibrous web that is deposited onto each side of the foam material isin a dry, tissue form prior to pre-wetting and subsequent water jetentanglement.
 16. A method, according to claim 9, where the fibrous webthat is deposited onto each side of the foam material is in a dry,individual fiber form prior to pre-wetting and subsequent water jetentanglement.
 17. A method, according to claim 9, where the fibrous webthat is deposited onto each side of the foam material is in a wet,individual fiber slurry form prior to water jet entanglement.
 18. Amethod, according to claim 9, where each of the fibrous webs that aredeposited onto each side of the foam material for both entanglementprocedures are dissimilar.